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BMW AG Motorcycle (F 650 GS). Manual - part 27

32.12

32 72 305

Removing and installing

throttle cable

–

Remove seat.

–

Remove left cover.

•

Disengage throttle cable from adapter (arrow).

•

Remove circlip (5) from throttle-cable holder and
disengage throttle cable.

•

Pull the cable out toward the handlebar.

•

Remove cover (4).

•

Remove fastener for throttle cable (1) from in-
strument cluster housing.

•

Disengage throttle-cable adapter (3) and disen-
gage nipple (4).

•

Remove the throttle cable.

•

Installation is the reverse of the removal proce-
dure: pay particular attention to the following.

Note:

Make sure that the cable is not kinked when in-
stalled.

•

Adjust throttle-cable play with adjusting
screw (5).

Throttle cable play................approx. 1 mm (0.04 in)

Tightening torques:

Cover of multi-function switch ........................ 1 Nm

E320170

E320180

32.13

32 00 454

Checking and adjusting

steering head bearing play,
renewing if necessary

(Inspections II and III)

32 00 454

Checking steering head bear-

ing play

•

Lift front wheel clear of the ground.

•

Move fixed fork tubes forward (arrows).

•

Adjust the steering head bearing if play is per-
ceptible.

32 00 454

Checking and adjusting

steering head bearing play,
renewing if necessary

(Inspections II and III)

32 00 454

Adjusting steering head bear-

ing play

Caution:

Cover or mask off the instrument cluster and trim to
prevent scratches.

•

Remove impact pad (2).

•

Remove clamp blocks (1).

•

Remove the handlebar and place it in front of the
instrument cluster.

•

Unscrew hex nut (5).

•

Release clamping screws (3) at upper fork
bridge.

•

Remove the upper fork bridge complete with the
ignition lock.

•

Remove counter-tube (4).

E360010

E320010

E320020

32.14

•

Slacken round nut (1) with pin-wrench adapter,
BMW No. 31 6 521, then tighten to 25 Nm.

•

Turn forks back and forth twice from lock to lock,
and leave the forks at the full left lock position.

•

Mark a 40 mm (1.58 in) arc with adhesive tape or
similar (arrow) around the circumference of the
locking plate at the steering head.

•

Align the mark on pin-wrench adapter,
BMW No. 31 6 521, with the right-hand end of
the marked arc.

Note:

40 mm (1.58 in) around the circumference of the
locking plate corresponds to an angle of rotation
of 60 °.

•

Turn the round nut clockwise until the pointer on
pin-wrench adapter, BMW No. 31 6 521, reach-
es the left-hand end of the marked arc.

•

Remove the mark/adhesive tape from the locking
plate.

Caution:

Check the mating faces of the fork bridge and
knurled nut, rub down with an oilstone if necessary
and clean.

•

Tighten the counter-tube.

•

Install fork bridge.

•

Firmly tighten locknut.

•

Tighten the clamping screws of the fork bridge.

•

Check play and freedom of movement.

Note:

Use the punch marks (arrow) to align the handlebars
as shown.

Warning:

Begin by tightening the front securing screws (as
viewed in the forward direction of travel) of the clamp
blocks, then tighten the rear securing screws.

•

Install handlebars and impact pad.

•

Lift front wheel clear of the ground and perform
final check.

–

With the front wheel off the ground, the weight of
the forks must be enough to turn the steering all
the way to the left and right full lock positions as
soon as the handlebar is moved away from the
straight-ahead position.

–

If local points of stiffness are detected when the
handlebar is moved to and fro, renew the steer-
ing head bearings.

Tightening torques:

Initial torque, round nut ................................ 25 Nm
Back off through angle of rotation .................... 60 °
Counter-tube to steering head bearing ........ 65 Nm
Hexagon nut to counter-tube ....................... 65 Nm
Clamp screws at fork bridge ........................ 21 Nm
Handlebar to fork bridge .............................. 21 Nm

E000220

31 6 521

E000230

32.15

Removing and installing left and
right handlebar levers

32 72 070

Removing and installing left

handlebar lever

•

Disengage clutch cable (1) from release lever.

•

Pull cable out of holder (2).

•

Remove the rubber grommet from the clutch le-
ver.

•

Make sure that slots in adjusting screw, locknut
and lever fitting (arrow) are in line.

•

Pull back cable shroud (3).

•

Pull the cable forward through the slot and disen-
gage the nipple.

•

Slacken the locknut at the handlebar lever

•

Slacken the pivot pin of the clutch lever.

•

Installation is the reverse of the removal proce-
dure.

•

After installing the cable, adjust clutch clearance
by setting distance “B” by turning adjusting
screw (4) on the clutch handlebar fitting.

•

Lock adjusting screw (4) with knurled nut (5).

Dimension “B” ............. 1.0...2.0 mm (0.04...0.08 in)

Tightening torques:

Locknut ......................................................... 5 Nm
Pivot pin of clutch lever .................................. 3 Nm

32 72 119

Removing and installing right

handlebar lever

•

Slacken the locknut at the handlebar lever.

•

Slacken the pivot pin of the handbrake lever.

•

Installation is the reverse of the removal proce-
dure: pay particular attention to the following.

Tightening torques:

Locknut of handbrake lever ............................ 7 Nm
Pivot pin of handbrake lever ........................... 7 Nm

E320150

E320160

E000200

32.16

33.1

Contents

Page

Technical Data

............................................................................................................................... 3

Removing and installing suspension strut

.....................................................................5

Removing and installing rear swinging fork

..................................................................6

Removing and installing needle roller races in rear swinging fork

............................7

Removing needle roller races ..............................................................................................................7
Installing needle roller races ................................................................................................................8

Removing and installing struts

.............................................................................................8

Removing and installing needle roller bearing in tension strut

...................................9

Removing needle roller bearing ...........................................................................................................9
Installing needle roller bearing .............................................................................................................9

Removing and installing angled lever

.............................................................................10

Removing and installing needle roller bearings and
needle roller races in angled lever

........................................................................................10

Removing needle roller bearings and needle roller races ..................................................................10
Installing needle roller bearings and needle roller races ....................................................................11

33 Rear wheel drive

33.2